ptt_ hydro static pressure testing of piping
TRANSCRIPT
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PREPAREDBY
NAPTT PUBLIC COMPANY LIMITED
CHECKED
BY ONSHORE COMPRESSOR STATION 4
PROJECT
APPROVED
BY
CERTIFIED
(PTT)NA
REV.
NO.
DATE REVISED
BY
APPROVED
BY
DESCRIPTION
D1 18-Feb-08 ISSUED FOR ITB
D2 11-Jun-08 ISSUED FOR ITB
SPECIFICATION FOR
HYDROSTATIC PRESSURE TESTING OF PIPING
SPC-0804.02-96.58 REV.D2
TOTAL 23 PAGES
AREA CODE OF SITE LOCATION
GENERAL AREA: 010
.
PTT PLC. CONTRACT NO. PTT PLC. PROJECT NO.
0804.02
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CONTENTS
SECTION
1. GENERAL ............................................................................................... 3
2. PRESSURE TEST SYSTEM........................................................................ 4
3. TEST WATER CRITERIA........................................................................... 6
4. TESTING ................................................................................................ 7
5. BLINDS FOR PRESSURE TEST .................................................................. 8
6. TEST PACK PREPARATION ...................................................................... 8
7. FIELD PIPE TESTING PROCEDURES..........................................................10
8. TESTING PREPARATIONS .......................................................................12
9. HYDROSTATIC TEST PROCEDURE...........................................................14
10. SAFETY ................................................................................................15
11. SENSITIVE LEAK TEST ...........................................................................16
12. ALTERNATIVE TESTS .............................................................................16
13. VESSELS AND EQUIPMENT.....................................................................17
14. INSTRUMENTS ......................................................................................17
15. CLEANING .............................................................................................18
16. REPORTS AND RECORDS .......................................................................18
17. TEST RECORDS .....................................................................................18
APPENDIX I MINIMUM THICKNESS OF BLANK FOR PRESSURE TEST.............20
APPENDIX II. DETAILS OF TEST FACILITIES ....................................................22
APPENDIX III. TEST LIMITS SYMBOL..............................................................23
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1.0 GENERAL
1.1 Purpose
This Specification specifies pressure and leak test procedure and acceptance
criteria of piping works to perform minimum quality level.
1.2 Scope of Application
This specification covers all the projects which to be done by CONTRACTOR
(here in after refer to CONTRACTOR) in piping construction works.
1.3 Definitions
1.3.1 Category D Fluid Service (per ASME B31.3) - A fluid service in which all the
following apply:
(1) The fluid handled is nonflammable, nontoxic, and not damaging to
human tissues
(2) The design gauge pressure does not exceed 10.35 bar
(3) The design temperature is between -29 C and 186 C.
1.3.2 Category M Fluid Service (per ASME B31.3) - A toxic fluid service in whichexposure to very small quantities of the fluid in the environment can produce
serious irreversible harm to persons on breathing or bodily contact, even when
prompt restorative measures are taken.
1.3.3 Damaging to Human Tissues (per ASME B31.3) - A fluid which, under
expected operating conditions, can harm skin, eyes, or exposed mucous
membranes so that irreversible damage may be done unless prompt restorative
measures are taken. (Restorative measures may include flushing with water,
administration of antidotes, medication, etc.)
1.3.4 Calculated Test Pressure:- The test pressure determined in accordance with
paragraph 4.0
1.3.5 Minimum Test Pressure - The lowest allowable test pressure gauge reading.
(the calculated test pressure plus the additional pressure resulting from the
static head of the test fluid)
1.3.6 Maximum Test Pressure - The highest allowable test pressure gauge reading.
(the pressure test rating of the "weakest" component in the test system)
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1.4 References
1.4.1 Related Code and Standards
Piping construction works shall be performed in accordance with ASME B31.3
and ASME section IX.
(1) ASME B31.3 Process Piping
(2) ASME SECTION.IX "Welding and Brazing Qualifications"
1.4.2 Related Specifications
Following specification shall be used as a supplementary of this specification.
(1) Piping Construction (SPC-0804.02-96.51)
(2) Internal Cleaning of Piping (SES-PR. Q2- 99-0204.10-3500-013)
1.5 Units
Unless otherwise specified, metric, Celsius and Kilogram units sell be applied
as the measurement system for the drawings and document to be submitted.
However, nominal sizes of piping component shall be in accordance with inch
system, which abbreviation in (B)
2.0 PRESSURE TEST SYSTEM
2.1 As large a piping system as practicable including its associated equipment
shall be hydro tested together as a unit, unless the difference among their
design pressures exceeds 15 percents of the lowest design pressure of the
system components.
The test pressure in the system shall be equal to the test pressure applied to
the system component of which the design pressure is the lowest among the
system as mentioned in the following paragraph.
Where piping systems of different design pressures are fully welded together,
then "cascade" pressure testing will be required, (i.e. complete the pressure
test on the higher pressure system prior to system closure welding and then
repeat full Pressure Test Procedure for the test of the combined systems at
the lowest pressure).
2.2 Heat exchangers, pressure vessels and fired heaters may be included in a testsystem, providing the system test pressure does not exceed the shop test
pressure of any of the included items.
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2.3 The following equipment and components shall not be included in the system.
The equipment shall be isolated from the system.
2.3.1 Rotary equipment such as pumps, compressors and turbines.
2.3.2 Safety valves rupture discs, flame arrest's, and steam traps.
2.3.3 Pressure vessels with sophisticated internals.
2.3.4 Equipment and piping lined with refractoriness.
2.3.5 Storage tanks.
2.3.6 Filters, if filter element(s) is not dismantled.
2.3.7 Heat exchangers of which tube sheets and internals have been designed for
differential pressure between tube side and shell side.
2.3.8 Instruments such as control valves, pressure gages, level gages, and
flowmeter. (excluding thermocouples)
2.4 Exclusions
The followings are excluded from the requirements of this specification:
2.4.1 Any package unit previously tested by the manufacturer in accordance with
the applicable codes.
2.4.2 Plumbing systems, which are tested in accordance with the applicable
plumbing codes.
2.4.3 Lines and systems which are open to the atmosphere such as drain, vents,
open discharge of relief valve, and atmospheric sewers.
2.4.4 Instrument impulse lines between the block valve at the process or utility line
and the connected instrument.
2.5 Although instruments shall normally be excluded from the system, process
lead lines shall be tested to the first block valve together with the piping
system.
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Any vents or bypasses downstream of the instrument's first block valves shall
be opened or the instrument shall be disconnected during the test to insurefull protection of that instrument.
2.6 The test shall be hydrostatic using water, except if there is a possibility of
damage due to freezing, or if the operating fluid or piping material would be
adversely affected by water.
Any other suitable liquid shall be used with CONTRACTOR'S approval.
2.6.1 Testing on site with Kerosene or other inflammable fluids or compressed airshall be avoided as far as possible (except where specifically called for) and
shall be carried out only with the approval of CONTRACTOR.
2.6.2 If a flammable liquid is used, its flash point shall be not less than 50C and
consideration shall be given to the test environment.
2.7 Pneumatic testing shall be considered for the following;
2.7.1 Gas, steam, or vapor lines when the weight of the hydro test liquid would
overstress supporting structures or pipe wall.
2.7.2 Piping with linings subject to damage by the hydro test liquid.
2.7.3 The instrument air headers shall be tested with dry-oil free air. The commodity
test may be used if the systems are completed and the instrument air
compressor is operational.
3.0 TEST WATER CRITERIA
3.1 Care shall be taken to insure the use of clean water for hydrostatic tests. Andthe sea water is prohibited to be used.
A suitable filter should be provided in the filling line to the systems in order to
remove foreign matter such as sand, rust or other particles in the proposed
test water.
3.2 Hydrostatic testing shall be performed using clam potable water with a
chloride content of max 50 PPM for austenitic steels. In case this requirement
can't be fulfilled the pipeline shall be reamed completely and flushed with
water fulfilling the above requirement of 50 PPM max of chlorides.
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4.0 TESTING
4.1 Hydrostatic testing of piping designed for internal pressure
The minimum hydrostatic test pressure at any point in the system shall be as
follows.
(1) Not less than 1-1/2 times of the design pressure.
(2) For a design temperature above the test temperature, the
minimum test pressure shall be as calculated by the following
equation.
Where:
Pt = minimum calculated hydrostatic test pressure (kg/cm2)
P = internal design pressure (kg/cm2)
St = allowable stress at test temperature (kg/ cm2)
S = allowable stress at design temperature (kg/ cm2)
See Table I, Appendix A, IASME 831.3 1
When St and S are equal, test pressure is 1.5 x P.
Where the test pressure as defined above would produce a stress in excess of
the specified minimum yield strength at test temperature, the test pressure
shall be reduced to a pressure at which the stress will not exceed the
specified minimum yield strength at the test temperature.
The maximum test pressure at which the stress produced will not exceed the
specified minimum yield strength may be calculated by the following equation:
Where:
Pm = maximum test pressure (kg/ cm2)
S = specified minimum yield strength at test temperature (kg/
cm2)
t = specified pipe wall thickness minus mill tolerance (cm)
D = outside diameter (cm)
E = quality factor (see ASME B31.3 table A-1 B)
4.2 Hydrostatic testing of Piping Designed for External Pressure. (Jacked limes)
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4.2.1 Lines in external pressure service shall be subjected to an internal test
pressure of 1-1/2 times the external differential design pressure but not lessthan a gauge pressure of 1.055kg/m2 (15 psi).
4.2.2 Jacketed lines, the internal line shall be pressure tested on the basis of the
internal or external design pressure, whichever is critical.
This test shall be preformed prior to completion of the jacket.
4.2.3 The jacket shall be pressure tested of the basis to the jacket design
conditions.
4.2.4 Where systems require hydrostatic testing through static equipment, the test
pressure shall be selected so as not to exceed vessel test pressure.
5.0 BLINDS FOR PRESSURE TEST
5.1 Plain test blanks shall be used with 1/16 inch flat asbestos gaskets for
blanking flat face, and raised face.
Provide full face blanks and gaskets for CL 125 connections.
However, where permanent operational blinds are installed, they may be used
for pressure testing.
5.2 Plate material, extra length bolts and gaskets, which are made at the Job Sitecould be used for testing. Maximum allowable hydrostatic testing pressure for
test blinds refer to appendix I.
5.3 Temporary spades and blanks installed for testing purposes shall be designed
to withstand the test pressure without distortion. Temporary test spades and
blanks shall be readily identifiable by painting a red color on the handle.
5.4 For ring joint flanges, spare ring joints shall be required as they are to be used
only once.
6.0 TEST PACK PREPARATION
6.1 General
6.1.1 CONTRACTOR will prepare a marked up of P & ID indicating the test limits.
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6.1.2 From the marked up PID, Subcontractor will divide the piping into suitable
Test Packs. The size of the packs may be revised by Subcontractor providedthat the specification for limits in Clause 6.2 below is complied with.
CONTRACTOR shall be notified of such revisions and will authorize
Subcontractor to proceed if said revisions meet the specification.
6.2 Test Pack Limits
6.2.1 Subcontractor shall not test through equipment without CONTRACTORs
written approval.
6.3 Test Pack Format
(1) Pressure test report for Piping
(2) Marked-up PID
(3) Blind check list
(4) Welding History Report and Welding Joint Marked ISO Drawing
(5) NDE Report.
(6) PWHT and Hardness test Report
(7) Post Test Punch List (CONTRACTOR + Client)
(8) Copies of reinforcing pad pressure test certificates.(If necessary)
6.3.1 Test packs will include the latest available revision of each isometric covering
the scope of the test.
(1) Test limits, and highlight line to be tested.
(2) Size (thickness') and location of all test blinds and including those
required at instrument connections e.g. orifice flanges.
(3) Identify location for the connection of the fill and drainage points for
the system.
(4) Vent points
(5) Drain points
(6) Location and range of pressure gauges to be used. Minimum (2)
Calibrate gauges enquired, one located at an accessible low point of
the test and one gauge located at the highest points on the test
manifold.
(7) Any otherspecial requirements such as chloride content if applicable.
(8) If required, temporary supports shall also be indicated in the test pack
(9) Any control valve, check valve, safety valves or other piping
accessories requiring removal,turning, or some other action should be
highlighted.6.3.2 Test packs shall also contain copies of PID's marked-up to show at least the
following information:
(1) Piping Field Test Pack Number
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(2) Specific Limits of that Test Pack Only.
(3) Testing Medium i.e. water, dematerialized / condensate water,or visual.
(4) Hydrostatic Test Pressure.
(5) Location of Test Blinds, Isolation valve, and Temporary piping
6.4 Test Pack Approvals and Distribution
6.4.1 After compilation of the test pack, the "Original" shall be submitted for
approval by Subcontractor under cover of a transmittal memorandum to
attention of CONTRACTOR's Engineer.
6.4.2 CONTRACTOR's Engineer will review packs and sign them as "Approved", if
acceptable.
6.4.3 The "Original" pack will be returned to Subcontractor who will then distribute
one (1) copy to CONTRACTOR's Engineer and (1) copy to CONTRACTOR Q/C.
6.5 Field Change Sheet (FS for piping)
6.5.1 CONTRACTOR's Engineer shall check the status of the affected test pack and
advise subcontractor as follows:
(1) For test packs not yet hydro tested
Subcontractor shall amend the original of the test pack referencing the
FS and Re-distribute including the FS.
(2) For test packs where hydrostatic test completed
CONTRACTOR will over-stamp the original test pack with "RETEST"
The re-stamp original will then be returned to subcontractor under
memorandum with an instruction to carry out the retesting.
Redistribution will then proceed per 6.4.3 (above).
7.0 FIELD PIPE TESTING PROCEDURES
7.1 Piping Installation Completion
7.1.1 Upon completion of the piping system component installation and seven (7)
days prior to testing, Subcontractor shall submit original test pack toCONTRACTOR that Piping Test Pack Number is ready for mechanical
clearance..
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7.1.2 Prior to submitting said memorandum Subcontractor shall have inspected the
Piping Test Pack for its completeness of installation and have organized /reviewed all required documentation for Welding History, Post Weld Heat
Treatment and Non-Destructive Testing.
7.1.3 CONTRACTOR will inspect the Piping System with prepare punch list.
7.1.4 Only after CONTRACTOR have verified and endorsed welding QC clearance
on the test pack and cleared all "A" Punch List items from the CONTRACTOR
punch list, will PTT/Consultant be notified by formal transmittal of the
CONTRACTOR endorsed Test Pack. On receipt of the Test Pack,
PTT/Consultant will review and inspect the QC documentation and punch
piping pressure test system".
7.1.5 PTT/Consultant will review and verify welding QC clearance and punch the
piping system tested. Only after PTT/Consultant have endorsed the welding
QC as acceptable and punch list items have been cleared, will the Test Pack
be formally returned to CONTRACTOR endorsed "Released for Testing"
7.1.6 If PTT/Consultant identify deficiencies in the Test Pack documentation,
welding QC documentation and or outstanding class A punch list items, theTest Pack will be formally returned to CONTRACTOR complete with attached
punch lists to be corrected and signed prior to resubmittal.
7.2 QC Clearance
During the time the Punch List is being prepared, the CONTRACTOR's QC
Section and Subcontractor QC Section shall proceed as follows:
7.2.1 Alloy Verification (For stainless steel material)(1) Where applicable, Subcontractor QC Inspector shall confirm that all alloy
verification data is complete.
(2) After checking alloy verification documentation, the Subcontractor QC
Inspector shall notify CONTRACTOR's QC Engineer that the
documentation is complete for checking/ verification by CONTRACTOR,
which may be reviewed by Owner.
7.2.2 Post Weld Heat Treatment (PWHT) and Hardness Testing
When applicable, submission of data for PWHT and Hardness Testing shall
Review with test data.
7.2.3 Non Destructive Testing (NDT)
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(1) After checking NDT records the Subcontractor's Inspection Group shall
notify CONTRACTOR's QC Engineer that documentation is "Complete"for checking/verification by CONTRACTOR, which may be reviewed by
Owner.
(2) In addition, a visual check shall be carried out in the field by
Subcontractor and CONTRACTOR/Owner Inspection to ensure all
welding has been correctly performed and that no remedial work is
required. If there is remedial work required it should be recorded on the
Punch List.
7.2.4 CONTRACTOR's QC Clearance
If CONTRACTOR's QC Engineer and/or Owner's Area Welding Inspectors find
outstanding items during this review/inspection he shall add these welding
items to a separate
"Welding Punch List" maintained with the welding / tractability isometrics for
the Piping Field Test Report. When all items are completed to the satisfaction
of CONTRACTOR and Owner's Welding Inspectors he will then sign the
"Original" Piping Field Test Report as ready to test.
8.0 TESTING PREPARATIONS
8.1 All joints, including welds, shall be accessible and left uninstalled, unpainted
and exposed for examination during the test. Joints previously tested in
accordance with this specification may be insulated or covered.
8.2 Piping designed for vapor or gas shall be provided with additional temporary
supports, if necessary, to support the weight of the test liquid. Where
required, temporary supports shall be specified in the pressure test
documents.
8.3 Lines which are counterweight supported shall be temporarily blocked during
testing in order to sustain the weight of the test fluid. Spring hangers which
have been provided with stops for carrying the test load normally do not
require additional temporary supports:
If this is not the case, temporary support must be provided before filling the
system.
8.4 Before Testing
8.4.1 Piping systems shall have been completely checked for correctness.
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8.4.2 All lines, vessels and equipment shall be checked to insure the entire system
can be completely drained after testing.
8.4.3 Vents or other high point connections shall be opened to eliminate air from
lines which are to receive a hydrostatic test.
8.4.4 Temporary gaskets may be used, which are not the same as permanent
gaskets, provided.
(1) Such use will not lead to damage of the flange faces.
(2) Temporary gaskets are removed immediately after completion of tests.
8.5 Vessels that are to be tested through shall be-reviewed in order to determine
the best method to prevent air entrapment when filling and to prevent a
vacuum when draining.
8.6 Short pieces of piping which must be removed to permit installation of a blind
or blank shall be tested separately.
8.7 Lines containing check valves shall have the source of pressure located in the
piping upstream of the-check valve so that the pressure is applied under the
seat.
If this is not possible, remove or jack open the check valve closure mechanism
or remove check valve completely and provide necessary spool piece or
blinds.
A notation shall be included on the Punch List that check valve flapper has
been removed. A new gasket shall be installed by Subcontractor wherever the
check valve bonnet has been disturbed. Where flappers have been removed,
valves shall be marked by tagging.
8.8 Systems that include expansion joints:
8.8.1 Expansion joints shall be excluded from pressure testing if the piping test
pressure is greater than the allowable test pressure of the expansion joint.
8.8.2 When a pressure test is required to be maintained for a period of time during
which the testing medium in the system would be subject to thermal
expansion, provision shall be made for relief of any pressure greater than the
maximum pressure.
8.8.3 Holding pins/spring stops shall not be removed from spring supports or
hangers until testing is completed and permission to remove is obtained from
the CONTRACTOR.
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8.8.4 Test equipment to be used during testing shall have suitable capacity for the
range of test pressures required. The range of pressure gauge(s) shall not beless than 11/2 nor more than four times that pressure.
8.8.5 All pressure gauges and chart recorders are to be calibrated specifically for
OCS#4 Project prior to use. If gauges have been used previously on other
projects or for other purposes, they shall be recalibrated. Validation of gauges
and chart recorders shall be for a maximum of 90days, however, recalibration
shall be required if the calibrated gauge/recorder is damaged or strained.
8.8.6 If the specified test, duration exceeds 8 hours, then a chart recorder shall be
used to record test pressure.
8.8.7 Prior approval must be obtained from the CONTRACTOR and Owner to include
vessels or inline equipment in the pressure test circuit.
8.8.8 (1) All necessary precautions shall be taken to ensure that, where
applicable, nitrogen purges in vessels or equipment are maintained and
ingress of moisture prevented.
(2) Purges shall not be released without CONTRACTOR approval, and shall
be reinstated upon completion of required work, unless otherwisedirected by the CONTRACTOR.
8.8.9 No equipment/instrument that is part of permanent works shall be used as
part of pressure testing equipment (i.e. pressure gauges, chart recorders,
valves, safety valves etc)
9.0 HYDROSTATIC TEST PROCEDURE
9.1 A systems test shall be employed. So as to hydrostatically test as much
piping as possible at one time. This test shall include one or more lines but
should not be connected to vessels and equipments.
9.2 The minimum test pressure for a system test shall be such that each line in
the system is subjected to a minimum test pressure in accordance with
paragraphs 4.1 or 4.2
9.3 The maximum system test pressure shall not exceed the pressure test rating
of any piping component.
9.4 Systems or sections of systems to be tested may be isolated by closed valves
provided the alive seat is suitable for the test pressure.
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9.5 Where a valve is not suitable, vessels, equipment or other piping not included
in the system to be pressure tested shall be disconnected from the system orisolated by blinds or other means during the test.
9.6 The normal location for the pressure test gauge is at grade near the pressure
test pump and at the highest point of the piping system. Readings may be
made at higher points providing the gauge pressure reading plus the static
head (0.97 kg/cm2/M) between grade and the point of measurement does not
exceed the maximum test pressure.
9.7 Hydrostatic test pressure shall be maintained for a sufficient length of time to
visually determine if there are any leaks, but not less than ten (10) minutes.
Test pressure shall not be required to be maintained in excess of two hours
after notification to CONTRACTOR.
9.8 After completion of the test, pressure shall be released by opening the valve
gradually so as not to endanger personnel or damage equipment.
As a rule, pressure releasing rate shall be 300 kg/ cm2/hr. For piping line for
which pressure releasing rate is to be specified, refer to specific job
requirements.
9.9 After completion of the test, the piping and equipment shall be drained
completely.
9.10 Piping systems shall be filled from a low point and filtered with a 10 micron
filter. During filling of the system all air or gaseous substance shall be vented
from high point to the maximum extent possible.
9.11 Hydrostatic test water will be discharged to the nearest storm water drains.
10.0 SAFETY
The safety related issues including but not limited to the following should be
addressed in Job Hazard Analysis (JHA) to be made by CONTRACTOR for
performance of Pressure Testing activities:
10.1 Appointment of CONTRACTOR's Test Controller who is in attendance and
responsible throughout the testing and inspects the welding during testing.
10.2 Appointment of the subcontractor's test controller who will be responsible for
ensuring safe testing in accordance to the specification.
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10.3 Display of safety warning signs to alert workers in the vicinity of the pressure
testing with line, identification.
10.4 Pressure test training and maintenance of a competency register as required
by CONTRACTOR Safety Plan.
10.5 Pressure rating for the test manifold and the test equipment and the required
inspection/testing.
11.0 SENSITIVE LEAK TEST
Piping required to have a sensitive leak test shall be tested by the gas and
bubble formation testing method specified in article 10, section V, of the
ASME boiler and pressure vessel code. If an additional hydrostatic pressure
test is required, it shall be done after the sensitive leak test.
12.0 ALTERNATIVE TESTS
This test shall be applied in accordance with ASME B31.3 Para 344.9 or
ASME B31.4 Para 437.1.4(b), if required, subject to approval from
PTT/Consultant
12.1 Void
12.2 Void
12.3 Initial Service Leak test
12.3.1 This test is applicable only to piping in Category Fluid service at the
owner's option.
12.3.2 A piping system used only for category ID fluid service may be tested at
the normal operating conditions of the system during or prior to initial
operation by examining for leaks at every joint not previously hydrostatic
or pneumatic tested in accordance with this specification.
12.3.3 Unless dictated otherwise by contractual provision, commodity testingshall be performed before mechanical completion.
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12.4 Non Pressure Piping shall be checked thoroughly by visual examination in due
course after installation
13. VESSELS AND EQUIPMENT
13.1 Hydrostatic testing of the following items is not permitted. However, they
may be pneumatically tested with adjoining piping system, if so designated in
the Field Pressure Testing.
13.1.1 Vessels or equipment supported by other vessels or equipment or by a
support Structure or foundation not capable of supporting the hydro test
load.
13.1.2 Vessels or equipment not capable of sustaining the hydro test load.
13.1.3 Vessels with internals or linings that would be damaged by the test fluid.
13.2 The following shall be excluded from all pressure tests:13.2.1 Pumps, compressors and turbines. Associated lube and seal oil systems
which could be impaired by the presence of water shall be tested with lube
oil.
13.2.2 Equipment and Seller furnished piping specifically recommended by the
manufacturer not to be tested.
13.2.3 Strainer and filter elements.
13.2.4 Vessels which do not satisfy impact requirements at pressure test
temperature
14.0 INSTRUMENTS
14.1 All instruments will be protected from damage when hydro testing process
and utility piping systems. Paragraph 2.3 outlines the status of instruments
during testing to insure protection.
14.2 Control valves shall have their bodies shop tested and need not be retested in
the field, but where valve does not restrict test pressure, valve may be
included in a system test. Valves shall be jacked open during test.
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15.0 CLEANING
15.1 Tested piping shall be internally cleaned to remove all remaining dust and
foreign matter by water flushing or blowing with air.
15.2 Flushing shall be done with clean water using hydrostatic test water where
possible. Water used for special flushing or cleaning of austenitic stainless
steel shall not contain more than 50 PPM chlorides, i.e.
15.3 Where special treatment is required, such as cleaning of compressor suction
and lube oil piping, a separate procedure shall be prepared by
CONTRACTOR'S Operations/Commissioning Group.
16.0 REPORTS AND RECORDS
16.1 As a minimum, the Subcontractor shall maintain records of all pressure tests,
records of all welding operations, including welder numbers, weld numbers,
and post weld heat treatment charts referenced to weld numbers, records of
all hardness tests, records of all cleaning, pressure gauges calibration sheets,
and when certification is required, all certification records.
16.2 All records shall be submitted and approved by the CONTRACTOR and shall
be submitted to the Owner.
16.3 Piping Field Test Report shall be prepared for each line segment of non
pressure piping.
17.0 TEST RECORDS
17.1 Records shall be made of each piping system test.
These records, when completed, shall be submitted as part of the test and
inspection certificates which are required for precommisioning.
Records shall include:
1) Date of test
2) Identification of piping system and any vessels or equipment tested
with the piping system.
3) Test medium
4) Test pressure and maintaining time
5) Minimum ambient temperature
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17.2 All test records, and authorized CONTRACTOR certifications shall be retained
in the Test Package records for turnover to the Owner. Test data base shall beestablished to monitor status and progress.
17.3 Where complete drainage is impossible, the system shall be flushed free of all
test water using boiler condensate or dematerialized water containing less
than five(5) PPM chlorides, alcohol, petroleum distillate or another suitable
flushing solution. Hot air drying is not acceptable in lieu of flushing, but water
may be blown out of pockets using air.
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Appendix I Minimum Thickness of Blank for Pressure test
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1. In case where piping diameter is 1B or under.
Test Pressure (kg / cm2) Thickness of Blind Plate (mm)
7 or under 1.6
8 14 2.3
15 40 2.5
41 60 3.2
61 115 4.5
116 210 6.0
2. In case where piping diameter is 26B or over, following formula shall be
applied to determine the thickness of blind plate.
Thickness of blind plate tm = t + c
dg : Inside diameter of gasket (mm) for raised face flanges, or the gasket
pitch diameter for ring joint and fully retained gasket flanges(inches)
P : design gauge pressure (psig)
S : stress value for material from Table A-1 B (psig)
E: quality factor from table A-1A or A-1 B
C : corrosion / erosion, plus mill tolerance allowance(inches)
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Appendix II. Details of Test Facilities
Schematic DWG for Supplying Source
(1) For Pneumatic Test (Not applicable)
(2) For Hydrostatic Test
Equipment List for Piping Pressure Test.
(1) Pump
- Test Pump (Pressurizing Rump)
- Water Supply Pump
(2) Air Compressor (for blowing, if required)
(3) Pressure Gauge (Two (2) or more)
(4) Rubber Hose W/Steel Wire Reinforced
(5) Temporary Piping with accessory
(6) Chemical Inhibitor (If required)
(7) Radios (Warlike Talkie)
(8) Other materials
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Appendix III. Test Limits Symbol
(1) Pressure Gauge hall be used and having graduation of 1.5 or 2 times of
test of more including gauge in pump discharge.
(2) PG shall be installed two or more including gauge in pump discharge.
(3) Calibrated gauge shall be used.
(4) Gauge be installed at the highest and the lowest point.